Holy, she's a faster builder than me and gets all the "Likes"!
Just kiddin', mate!
You are doing an absolutely marvellous job. However, my last question still stands, did you re-scale NJ's version or did you print it "as is"?
As for the alignment problems, I guess these were caused by the way the model was constructed (hand-drawings). It's good to know that you have mastered the issues.
BTW, a few years ago I found a terrific DS9 on the SketchUp Warehouse site:
https://3dwarehouse.sketchup.com/model.html?redirect=1&mid=10e3882c71567f28bdbd60b756975f5d
It is a great basis, highly detailed and superbly made for papercrafting. There are no intersections and all panels are raised, meaning that there are LOTS and LOTS of greeblies. The best thing is that if you get rid of the rims of the raised parts you see that the model is so very well cleaned up that the area which is covered by the raised panel has a hole in the exact shape of the greeblie. This can be used as a mark for aligning the panels on the final model:
I paused on this one because it is a hell of work to unfold so many parts and I had no full Pepakura license at the time when I started, so I was unable to save the current state of the unfold and had to print what I had done to a pdf and stay with it (this explains why the parts are so scattered all over the place, too
). Maybe I will return to that project when I have more time.
P.S.: I think the reactor screams for a red LED..!